a FOREWORD In this booklet are mainly explained the construction, the operations, the inspections and the adjustments of SUZUKI TS125, To give satisfaction to all customers during a long life of the motoreyc portant for the mechanic to prevent even a trivial trouble of the motorcycle by periodical it is most im. Inspections and adjustments. However, if any trouble might happen, quick and suitable steps should be requested to the mechanic. To cope with the above cases, we hope all the mechanics will read this booklet repeatedly and comprehend thoroughly its contents. By the way, the metric system is adopted in our factory, and is also used in this booklet. Further, for mechanics in some foreign country who are not strong at the metric system, dimensions in the foot-pound system are described in brackets ( October, 1970 $ SUZUKI moTOR CO.,LTD. EXPORT SERVICE SECTIONTABLE OF CONTENTS 8-1. Work with Engine In Frame «~~~ . ENGINE ~~ a TIPS ON OPERATING «"" RIGHT AND LEFT SIDE VIEWS ~~ PERFORMANCE CURVES ~ SPECIFICATIONS SPECIAL FEATURE ~~ SPECIAL TOOLS ~~ TROUBLE SHOOTING 8-2. Work with Engine Removed From Frame or WT 8-3. Tips On Disassembling And Assembling Engine re 21 8-4. Cylinder Head ~~ 8-5. Cylinder -- B46. Piston svssssssseesseesnseenneeeenesennetenstenesttnaneennettnerteesstssineitna 24 8-7. Piston Rings - 25 8—8. Piston Pin Bearing - - 27 8-9. Flywheel Magneto -. 27 8-10. Drive Sprocket 28 8-11. Oil Pump & Oil Lines ++ 29 8-12. Clutch o 8-13. Kick Starter ceseeeeeeeeeee 8G 8-14. Gear Shifting Parts Outside Crankcase +10 42 8—15. Primary Pinion ~ . 44 8—16. Crankcase & Relative Parts -- a 459. TRANSMISSION ~ 9-1. Exploded View Of Transmission +--+ 52 9-2. Gear Shifting Parts Inside Crankcase ~~ 55 10. CRANKSHAFT 57 11. NEUTRAL INDICATOR SWITCH ~ 59 12. CARBURETOR ~~ sa 60 13. ENGINE ELECTRICAL EQUIPMENT 65 13-1. Flywheel Magneto 6B 13-2. Specifications Of Magneto - 66 13-3. Spark Plug o sees BT 13-4. Inspection And Cleaning Of Plug 68 13-5. Contact Breaker - 68 13-6. Ignition Timing - seeeseernneee 69 13-7. Primary Coil 71 13-8. Ignition Coil seeeenseeeene 72 13-9. Condenser --- 73 13-10. Charging System ~~ 74 13-11. Lamp Coil e---> 74 13-12. Selenium Rectifier ----- 74 13-13. Battery ~~ : 75 14, 14-1. Front Fork ----- 14-2. Steering Stem And Relative Parts ~ 14-3. Drive Chain - CHASSIS; 14~4, Front And Rear Wheels ~ enn ereecier BO) 16. 16. 17. 18. 19. TIGHTENING TORQUE FOR BOLTS AND NUTS ~~ sereareanests. 9M. PERIODICAL INSPECTION SUZUKI TS125 WIRING DIAGRAM (Standard Spec.) SUZUKI TS125 WIRING DIAGRAM (For USA & CANADA) EXPLODED VIEW OF TS125 ENGINE,1. TIPS ON OPERATING Please advise: your customers to follow these tips to keep the motoreyele in peak can. dition and it will give top performance at all times. 1-1, Breaking in The life of the motorcycle depends on the breaking-in of the engine and the way in which the motorcycle is treated. Just a8 with @ newborn baby, it must give the best care possible, During the breaking-in period, do not ride the motoreycle at high speeds nor allow the engine to run wide open, Keep to the specified breaking-in engine r.p.m. limits. Gradu- ally raise the engine r.p.m. as the covered milage increases, for first 800 km (500 mi)......... . below 5,500 r.p.m. for the next 800 km (500 «+ below 7,000 r.p.m. Always keep the engine r.p.m. below 8,000 as averstraining the engine has a bad effect on it. Do not allow the pointer of the engine tachometer to stay in the red zone (8,000 10,000 r.p.n), 1-2. Fuel ‘The TS125 engine requires no gas/oil mixture as fuel unlike conventional 2-strake engines. The engine’s moving parts such as crankshaft, crankshaft bearings, con-rod, piston and cylinder wall are positively lubricated by fresh oil which is separately prossure-delivered from the variable displacement oil pump. This unique force ciling system is called “Suzuki C.C.1.". Put gasoline only in the fuel tank and lubrication oil in the oil tank. Recommended fuel for the TS125 as for all Suzuki motorcycles, is @ regular grade gasoline. For the Suzuki C.C.I. system, use of Suzuki C.C.|. Oil is highly recommended, but if it is not available, non diluent (non-self mixing type) Two Stroke Oil or Outboard Motor Oil with around SAE #30 can also be used. 1-3. Genuine Parts When replacing parts, always use genuine Suzuki parts, which are precision-made under severe quality controls, H imitation parts (not genuine parts) are used, good performance cannot be ‘expected from the motorcycle and in the worst case, they can cause a breakdown, Fig. 1-1 Suzuki genuine pars 12. RIGHT AND LEFT SIDE VIEWS: SUZUKI TS125 Fig. 2-23. PERFORMANCE CURVES. 3-1. T1256 Engine Performance Curves4. SPECIFICATIONS Name Suzuki TS125 1 Dimensions and Weight Overall length Overall width Overall height Wheelbase Ground clearance Tires front rear Dry weight 2,080 mm {80.7 in} 245 mm {23,26 in) 1,100 min (43.3 in} 1,310 mm (51.6 in) 235 mm {9.25 in) 2.75 — 19" 4PR 3.25— 18" 4PR 90 kg (231 tb) 101 Performance Maximum speed Climbing ability 105~ 112 kph (65~ 70 mph) 35° Braking distance 8m (26.0 ft) — @36 kph (22 mph} 0 Engine Maximum horse power 13hp 7,000 r.p.m. Maximum torque Type Cylinder Bore X stroke Piston displacement 1,36 kgm (9.8 fel) @6,500 r.p.m, 2 cyele, air cooled single cylinder Sleeved aluminum 86 X 50 mm (2.20 X 1.97 in} 123 ce (7.6 cu in) Corrected compression ratio 67:1 Starter Kick (PRI) Fuel system Carburetor VM24SH Air cleaner resin-processed paper filter Fuel tank capacity 7 Ite, (2.0/1.54 gal, US/Imp) (0 Lubrication System Engine Oil tank capacity Gear box C.C.I, (Posi Force Lubrication) 1.1 Itr (1.2/0,98 gt, US/Imp) 0.55 Itr (0.58/0.49 qt, US/imp}Gi Ignition system Spark plug Ignition Ignition timing 1 Transmission system Clutch Specds Gear shifting Gear ratios Low (Overall reduction ratio) 2nd 3rd ath Top Primary reduction ratio Final reduction ratio 1 Suspension Front suspensian Rear suspension Ci Steering - Steering angle Trail Castor Turning radius 0 Brakes Front brake Rear brake NGK B-77HC Flywheel magneto 21~23° (2.20~ 2.62 mm) BTDC, Wet multi-dise 5 speeds, constant-mesh Left foot, lever-operated return change 32.65: 1 21611 14.8451 11.8751 1 1 1 9.50 3.56 3.33 (e716) (50/15) hydraulically damped telescopic fork hydraulically damped swinging arm (5 ways adjust) 40? (right & left) 125 mm {4.9 in) 60° 2,350 mm (92.6 in) Right hand, internal expanding Right foor, internal expanding U Electrical equipment Generator Battery Fuse Head! lamp Tail/orake lamp Turn signal lamp Neutral indicator lamp Speedometer lamp Turn signal indicator lamp High beam indicator lamp Flywheel magneto 6V 4AH 15a, 6V 25/25W 6y 3/10w (For U.S.A. & CANADA 6V 3/21¢p) ev Ew x4 (For U.S.A. & CANADA Optional) ev aw 6v 3W 6v 1.5 6v 1.5W * The specifications subject to change without notica5. SPECIAL FEATURE 5-1, SUZUKI C.C.I. (POSI-FORCE LUBRICATION) — World's Most Advanced System — Suzuki C.C.I., which is now well known, is the unique lubricating system developed by Suzuki. This system supplies the correct amount of oil under pressure directly to the engine stressed points such as crankshaft bearings, con-rod big end and cylinder wall that need lubrication. Oil is not mixed with gasoline for this 2-cycle engine or fed through the carburetor as seen in some 2-cycle engines, so that oil is not thinned by gasoline before it reaches its destination, assuring more effective and positive lubrication. 5-1-1. Explanation of mechanism Fig. 5-1 SuzukiLubrication oil is supplied through two oil outlet pipes by an cil pump under pressure, and is completely separate from the gasoline supply. The left side outlet pipe supplies oil directly to the left crankshaft bearing After lubricating it, the oil passes through a passage in the crankpin and lubricates the needle roller bearings in the connecting rod big end. The oil which lubricates the big end is scattered by a strong centrifugal force, thus lubricating the small end of the connecting rod, The oil which is delivered to the right side outlet pipe is Supplied to the cylinder through the hole on the left crankcase and lubricates the cylinder wall, The right crankshaft bearing is lubricated by the transmission oil The total arnount of oi! pumped is regulated by the oil pump control lever operated by the oil pump control cable, which is synchronized with the throttle cable and varies with the throttle opening. At the same time, the amount of oil supplied is also controlled by the engine speed thus the correct amount of oil, exactly the amount needed by the engine, is always supplied, Suzuki C.C.I. is the most ideal lubrication system for the two-stroke engine. ‘The outstanding advantages resulted from PFL: 1. Pre-mixing of gas and oil is unnecessary, 2. The engine life is doubled because of direct feed of fresh oil to the stressed parts needing lubrication, 3. No cloudy exhaust fumes are emitted, 4. Carbon accumulation is minimized because very little oil is burnt, ©. Oil expenses are lowered, for no surplus oil is consumed, 6. Engine stays clean since a fuel mixture is not used, 5-2. Convenient Primary Kitckstarter The primary kicksterter enables the engine to be started either in gear or in neutral,6. Special Tools For SUZUKI TS125™@ SPECIAL TOOLS Special tools listed here are used to disassemble, assemble and perform other maintenance and services. ordinary tools and also do not damage parts. It is recommended to provide these special Lools as shop equipment. These special tools make work easy which cannot be done simply with No. Name Service. 1, 09900-15202 | Special tool box 2, 0991-50110 | Oil seal remover remove oil seals, 3, 09910-10710 | & mm stud installing tool install 8 mm studs 4, 03920-70111 | Snap ring opener fit or remove circlips 5, 09910-20111 | Piston holder prevent crankshaft from turning 6, 09910-82810 | Crankshaft assembling too! —_ | assemble crankcase 7. 08930-30113 | Flywheel rotor remover remove flywheel rotor 8, 09920-52810 | Clutch seleve hub halder hold clutch sleeve hub 9. 09920-60310 | Clutch sieeve hub holder handle hold clutch sleeve hub 10. 09920-70120 Spring apenner {or temove rear sprocket drum irclip 11, 09910-92810 | Crankshaft remover separate crankease 12, 09913-70122 | Bearing & oll ea installing too install bearing & ol seal 13, 09913-80110 | Bearing & oil seal installing too! | install bearing & oil seal 14, 09990-40113 | Flywheel rotor and hold flywheel rotar to loosen nut Engine sprocket holder and hold engine sprocket 15. 09930-10111 | Spark plug wrench loosen or tighten spark plug 16. 09900-28102 | Electro tester Check all electrical equioment 17. 09930-20111 | Contact point wrench chock contact point gap 18, 09940-60110 | Spoke nipple wrench lopson oF tighton spoke nipples 19, 09940-10121 | Steering stem nut wrench loosen or tighten steering stem nut 20, 09910-70110 | Exhaust pipe cleaner remove carbon from exhaust pipe 21, 09931-00111 | Timing gauge check ignition timing 22, 09900-27002 | Timing tester check ignition timing 23, 09941-00110 | Front fork outer tube nut loosen or tighten front fork outer ‘wrench set tube nut 24, 09920-20810 | Clutch spring hook remove or install clutch spring pin AAs regards the details, refer to the Suzuki Special Tool Catalogue.7. TROUBLE SHOOTING When trouble occurs with a motorcycle, it is improtant to find the source of the trouble a8 rapidly as possible, It is also necessary to parform only the work required to repair the machine and not bother with parts which are functioning correctly. The list of possible troubles and their courses given below should help the service man to repair motorcycles quickly without loss of effort. 7-1. If Engine is Hard to Start Check fuel in the fuel tank first. When a proper amount of fuel is in the tank, check the following points, Order Description Check Points Action 1. Check to sce that fuel * If fuel does not enter into carburetor: flows into carburetor. 1. Fuel strainer clogged Remove and clean 2. Fuel pipe clogged or damaged Clean or replace 3. Fuel clock clogged Clean with a wire 2, Check to see that spark If blue or hot spark jumps in the jumps in spark plug (turn spark plug, check the following engine with kick starter). points. 1. Ignition timing Adjust 2. Fuel Check mixture 3. Carburetor float Adjust or replace 4, Engine compression See specifications » If the spark is weak or red. 1. Damage in spark plug Replace 2. Incorrect spark plug gap Adjust 2, Damage in spark plug cap Replace 4, Dirty contact breaker points Clean and adjust 5, Bad insulation in condenser Replace 6. Damage in ignition coil or Replace primary coil + If there is no spark. 1, Damage in spark plug Replace 2 Dirty or wet spark plug Clean 3. Incorrect spark plug gap Adjust 4. Dirty or incorrect contact Clean and Adjust breaker paint gap 5, Bad insulation in condenser Replace 6, Damage in ignition coil or Replace primary coil 7. Damage in ignition switch Replace 8. Damage in wiring harnesses Repair or replace 102, Check to see that engine * If engine compression is improper. compression is proper. (Turn engine with kick starter) 1, Worn cylinder and piston rings Repair or replace 2, Stiff piston ring on piston Repair or replace 3, Damage cylinder head gasket Replace 4, Damaged piston Replace 5. Imrpoperly tightened spark plugqTighten securely 6. Improperly tightened cylinder Tighten securely head 7. Gas leaks from crankcase join: Repair or replace ing surface 8. Damaged cylinder or cylinder — Replace head These throe things—fuel, spark and compression—are basic points for engine operation. To find troubles, first check these points. 7-2. Mf Engine Does Not Run Smoothly Order Description Check Points Action 4, Turning throttle grip, + Engine rom increases, but motor check ta soe that engine cycle does not run fast. rom increases. 1. Cluteh slippage Adjust clutch cable or replace clutch plat * Ifengine rom does not increase. 1. Imrpoperly adjusted carburetor Adjust 2. Dirty air cleaner Cloan 3, Clogged fuel tine Clean 4, Improperly adjusted ignition Adjust timing 5, Clogged exhaust pipe and Clean muffler 2, Turning throttle grip, * When rapidly accelerated, engine check to sae that engine does not run smoothly. runs smoothly. 1. Improper ignition timing ‘Adjust 2. Improperly working contact Adjust breaker 3. Improperly adjusted carburetor Adjust 4. Dirty spark plug Clean and adjust # Engine does not run smoothly at low rpm 1. Too early ignition ‘Adjust 2. Dirty contact breaker Colan and adjust 2. Dirty or improperly adjusted Clean and adjust spark plug 4. Improperly adjusted carburetor Adjust pilot air adjusting screw 5. Clogged or damaged fuel line Clean or replace 6. Imrpoperly working contact Adjust n breaker+ Engine does not run smoothly at high rpm, 1. Clogged or damaged fuel line Clean or replace 2 Dirty or improperly adjusted Clean and adjust. spark plug 3. Improperly working contact Adjust breaker 4, Too late ignition (Retarded) Adjust Improperly adjusted carburetor Adjust Dirty air cleaner Clean or replace 3 Check to see that engine See “If engine is hard to start” Compression is proper section, 4, If engine overheats, 1, Improperly adjusted oil pump Adjust control lever adjusting marks 2. Airin oil fin Remove air 3! Improper ignition timing Adjust 4, Carbon deposit in combustion Clean chamber 5. Carbon deposit in exhaust pipe Clean and muffler 6. Incorrect spark plug heat range Replace with colder plug 7, Low grade oil used Roplace with correct oil 8. Clutch slippage Adjust or replace plates 9. Brake dragging Adjust 10, Drive chain too tight Adjust If Abnormal Noise is Heard in Engine Deseript Check Points Action 1, Too big clearance between Repair or replace piston and cylinder 2. Toa big clearance between ——_—Replace piston piston rings-and grooves 3, Pisotn rings stiff with carbon Clean 4, Worn con-rod big end Replace 5, Worn con-rod small end bearing Replace 6. Damaged piston rings Replace 7. Too early ignition timing Adjust 8 Defective primery pinion and — Replace gar 9. Worn crankshaft bearings Replace 10. Defective transmission gears Replace 11. Defective transmission shaft. Replace Bearings 7-4, If Engine Overheats If engine overheats at high speed running after itis broken in, check to see if the oiling systam is in good condition, the brake is dragging, or cylinder cooling fins are dirty. Inspect the following points, 2Order Description Check Points ‘Action 1. Check to seeifoiling 1. Improperly adjusted oil pump Adjust system is in good control lever adjusting marks condition 2. Air in oil lines Remove air 3, Cheked oil tank breather pipe Correct 4, Incorrect oil used Use prescribed oils 2, Check to see if engine * Too high compression compression is higher 1. Carbon deposits in combustion Remove carbon chamber deposits 2, Too thin cylinder head gasket Replace 3. Chack carbon deposits * Check for carbon deposits in Disassemble end re muffler, exhaust pipe, exhaust move carbon deposits port and combustion chamber 4, Check to see that piston * Piston rings stiff from cerbon Remove carbon. rings move smoothly in deposits deposits grooves, ©. Check to see that the Clutch slippage causes overheating Adjust clutch cable or clutch works properly _of engine replace plates 6. Check to see that the Adjust ignition timing is correct 7. Drive chain too tight Adjust 8. Incorrect spark plug Replace with colder heat range plug 9. Too lean fuel mixture ‘Adjust carburetor 7-5. If Engine Stops Abruptly During Running If engine Stops during running, first check to see if there is fuel in the tank, wiring harnesses are connected etc, and inspect the following paints. Order Description Check Points Action 1. IFengine stops abruptly 1. Seized piston Repair or replace 2 Seized crankshaft Repair or replace 8. Seized transmission gear Repair or replace 4, Spark plug bridged Clean 5, Defective ignition coil Replace 6, Troubles in ignition system Repair or replace 7. Clogged fuel line Clean 2. Ifengine stops gradually 1. Loose spark plug Tighten securely 2. Loose cylinder head Tighten securely 3: Damaged cylinder head gasket Replace 4, Clogged fuel fine Clean 13,7-6. effective Brakes First check the play in the front brake lever and the rear brake pedal. Inspect the follow- ing points, Order Description Check Points ‘Action 1. Insufficient braking 1. Worn brake linigns Reoplace 2. Dirty brake linings Clean 3. Brake drum worn or dirty with Fleplace or clean mud or water 4, Worn brake cam Replace 5, Improperly working brake wire Adjust or replace 2, Brake drags 1, Rust in moving aprts Repair 2, Moving parts dirty with oil or Clean and apply a pro: insufficient lubricant per amount of lubricant 3, Abnormal noises are 1, Worn brake linings Roplace heard 2. Foreign particeles on brake Clean linings 8. Dirty brake drum Clean 7-1. Defective Clutch Order Description Check Points Action 1. Clutch slippage 1. Improperly adjusted clutch Adjust clearance 2. Fatigued clutch springs Replace 3. Worn clutch plates Replace 4, Worn clutch reloaso screw Replace 2. If clutch drags 1. Too heavy oil Replace 2. Defective clutch plate operation Repair or replace 3. Improperly adjusted clutch ——-Readjust. cable 7-8, Gear Shiftings Troubles First check the clutch operation and amount of ail in the transmission chamber. Inspect ‘the following paints, Order Description Check Points Action 1. Gear engagement * If gears do not engage, check for 1, Damaged cam groove Replace change cam 2. Shifting forks not moving Repair scoring or burrs smoothly on cam 3. Damaged gear shifting fork Replace 4. Seized gears Replace 5, Damaged gear shifting shaft Replace 42, Gear shitting lever 2. Jumping out of gear + If gear shifting lever does not return to normal position, check for: 1 Damaged gear shifting shaft return spring * If the gears disengage while running, check for: 1 2. 3. Bad operation gear shifting cam stopper Wom or bent gear shitting fork Wor gear or driven gear wheel dog teeth Replace Inspect and replace if necessary Replace Replace gear or driven gear wheel Order Description Check Points Action 1, Handlebar stiff 1. Steering stem lock nut too tight Adjust 2. Bent steering stem Ropair or replace 3. Damaged steel balls Replace 2. Handlebar not stable 3, Wheel is not true he Noo see pNegaLS Incorrect wheel alignment Play in frant wheel fitting Damaged steel balls Bent fork stem Wom or damaged bearing races Bent front forks Bent swinging arm Incorrect wheel balance Up-and-down play in hub bearings . Deformed wheel rim Loose spokes Chain too tight Loose swinging arm fitting Warped frame Incorrect tire pressure Ropair Repair or replace Replace Repair or replace Adjust Replace Repair or replace Repair Adjust Tighten Replace Correct, 168. ENGINE 8-1, Work with Engine in Frame These parts can be inspected, adjusted and replaced without removing the engine from the frame. When removing the crankcase cover for repairing clutch, gear shifting shaft, etc, first remove the oil drain plug located on the side of the right crankcase cover to drain the oil from the gearbox and clutch chamber. Parts Operation |Retighten, inspect, adjust gep, remove carbon, replace; Inspect gasket for flexibility, replace Retighten cylinder head bolts; Remove carbon, check far war- 1, | Spark Plug 2. | Cylinder Head page, repair Cylinder Head a, [Glin Inspect, replace Remove carbon from ports; Check for burned spots and scor- 4, | evlinder ing, repair; Check for wear, rebore Remove carbon from heads and ring grooves; Inspact for burned Piston spots and scoring, repair or replace; Check piston pin holes land ring locating pins for wear, replace Piston Ring Inspact for wear and tension, replace Piston Pi Inspect for wear, replace Comrod Small , . | End Needle Bearing "SP2Ct for wear, rep (Check contact point and ignition timing, adjust; Check point surface for pits, polish Check condenser, replace 5, 6. 7, 8, [Piston Pin Circlip [Inspect for warpage and dropping out, replace or repair 9, 10, Flywheel Magneto 11, | Neutral Indicator Switch 12, [Engine Sprocket —_|Inspect for wear, replace 13, [Primary Pinion | Inspect for backlash, replace Inspect cork plates for wear, replace, Inspect clutch springs ‘or free length, repair or replace; Inspect sleeve hub for 14, | Clutch stepped splines, replace; Check housing for loose riveting and burrs an grooves, repair or repalce, chekc gear backlash, replace, check push rod for bent, replace inspect shaft return spring for tension, replace, Inspect for wear, replace [Check control lever adjusting marks, adjust; Check oil lines for air, remove Check play in throttle cable, adjust; check float level, adjust: check fuel mixture for various throttle openings, adjust; Clean Inspect for wire break, repair or replace; Inspect gasket, replace 16, | Gear Shifting Shaft 16. | Oil Pump 17. | Carburetor 168-2 Work with Engine Removed from Frame Remove the engine from the frame and separate the crankcase into right and left halves for these jobs, Parts Operation 5 TTSp@GI Tor Shaka, repair or replaon Chock basrngs Tor wear, __ [Seana replace; Check oil seals for leakage, replace 2 Transmission Check gears and shafts, adjust or replace; Check bearings and vet bushing ple Goarshitting ) ImSB20 Siting cam_ groove for damage, repair or replace: [Gear shitting | [fspoct shiting forks Yor bumed spats and wea, repair or 83 Kick starter system replace Inspect pinion for worn ratchet, replace; Inspect pawl and pavil spring for weer and tension, replace; Inspect kick starter shafl return spring, replace Removing Engine From Frame Before begining the removal operation, thoroughly clean the engine with a steam cleaner or cleaning solvent to remove road dirt. Work according to the order of the following figures, Fig, 8 Loosening drain pug to drain fut gearbox ol Fig. 4 Removing tachometer cable "7a Fig, 8-11 Unserowing earburetorfting nuts 18 Fig. 8-8 Removing frame att cover >» Fig, 8-12 Removing carburetor from engineA aN Fig. 8-13 Diseonnscting magneto wit - Fig. 8-20 Removing oil pur eableFla, 8-27 Femeving engine mounting bolts 20To install the engine into the frame reverse the order of removal. Connect wires accord ing to the wiring diagram, Check the oil pump control lever adjusting marks. Inspect the clutch operation. 8-3, Tips on Assembling and Disassembling Engine The Engine is the heart of the motorcycle and consists of precisely manufactured parts, which must be handled and assembled most carefully. When working on the engine, keep your hands and tools clean at all times. Before beginning work, prepare work benches, necessary tools, clean rags and cleaning solvent for washing parts, 8-4. Cylinder Head 8-4-1. Removing Remove 4 nuts with a 14mm wrench and take off the cylinder head, Be sure to loosen the nuts by in a criss-cross fashion to prevent cylinder head warpage. 8-4-2. Servicing ‘A, Removing carbon deposits Although carbon accumulation has been min- fig g 4-1 Loosonng omer of cylinder head imized by the adoption of Suzuki C.C.., it is nu advised to remove carbon deposits in the com bustion chamber with a screw driver bit or something like that every 6,000 km (4,000 mi) ‘taking care not to damage dome surface, Note that carbon deposits decrease heat radiation a8 well as increasing engine compression with tesultant engine overheating, 8. Removing dirt accumulation Dirt accumulated between the cooling fins can cause engine overheating because it affects ‘thermal radiation adversely. To clear the cylinder head of dirt accumulation, Fis 8-4-2 Ureerewing cylinder head nut sorape with @ screw driver and then brush with cleaning solvent or gasoline. aC. Checking Warpage The cylinder head is always exposed to extreme: ly high pressure and temperature, so they can warp is used for a long time. To repair a warped cylinder head place it on a surface plate and grind the face flat on it with first #200 and then # 400 emery paper. 8-4-3. Installing Place cylinder head gasket between the cylinder head and cylinder and fit the cylinder head with nuts. Tighten then diagonally just the same as when loosening. Be sure to fita flat washer under the oylinder head nut, Cylindar head nut tightening torque 200~ 250 ka-cm (14.47~18,09 1b-F0) 8-5. Cylinder 8-5-1, Removing Clean the crankcase around the cylinder base to prevent dirt from entering into the crankcham- ber before removing the cylinder. The cylinder can be removed easily by pulling it off of the four studs screwed into the crankcase, 8-5-2. Servicing Carbon deposits accumulated around the ex- aust port increase resistence to the passage of exhaust gas and cause loss in engine power and engine overheating. Remove carbon deposits every 6,000 km (4,000 mi) with a screger or screw driver. Be careful not to scratch or score the cylinder wall or passage surface. 2 Fl 8-4-3 Removing carbon doposits Fig. 8-5-2 Removing cabon deposits8-5-3. Inspecting Check the cylinder for wear. To determine the amount of wear, measure the cylinder bore with acylinder guage. Measure the cylinder bore from front to back and from side to side at throe points, If the figure oblained by subtracting the smallest meas: urement from the largest one is over 0.06 mm (0.002 in} rebore the cylinder. Limit 0,05 rm (0,002 in) Operation Rebore cylinder When refinishing the cylinder oversize, first add to the standard cylinder bore size the oversize step apparently required to clean up the bore This gives the exact size to which the cylinder should be refinished, Check carefully with an accurate cylinder guage to be sure of refinishing to this size. If this is accurately done, an over: size piston will fit with normal clearance. Over size pistons are provided in 0.6mm (0.02in) and 1.Ornm (0.04in} sizes. 56.000-56.015 mm (2,20472—2,20531 in) Standard cylinder bore It must be noted that the edges of the porting need to be rounded after reboring the cylinder. If they are not rounded, rapid wear of the piston rings and unpleasnat cylinder noise will result, Round the edges with a hand grinder or file, Fig. ©-5-9 Measuring cylinder bore 6 nm(o.24 in} cena Fig, 8-5-4 Points to be measured 238-6. Piston 8-6-1. Remi Fig, 8-6-1 Removing piston pin cielip 8-6-1, Inspecting ‘A, Piston ring locating pin Excessively worn locating pins allow piston rings to turn in the grooves with unpleasant noise and in the worst case, to catch on the ports resulting in the break of the engine itself. Replace the piston complete with a new one. B, _Piston-cylinder clearance The staidardpiston-oylinder clearance is 0.060-0.070 mm (0.024—-0.0028 in) The clearance is determined by subtracting piston diameter from cylinder diameter. The cylinder measurement should be taken at 9mm (0,35 in) above the exhaust port, and the piston skirt 90° from the piston pin holes, Use a cylinder guage to measure the cylinder bore and ‘an outside micrometer to measure the piston diameter, Piston-cylinder clearance Standard Limit Operation: {0.060-6,070 mm) | 0.25mm | Rebore cy- {0,0024—0.0028 in) | (0.0978 in}| linder or re- place pistons 28 Fig, 8-6-2 Piston rng locating pin i 23n(0.0i0) a. Fig. 8-6-4 Point to be ractured eo Fig, 2-6-5 Meaeurng piston diameterC. Checking wear and damage: Inspect the piston pin holes and piston ring locating pins for wear and the piston surface for burned spots, scratches, ete, Excessively worn locating pins allow piston rings to turn in ‘the grooves and possibly catch on the ports of the cylinder. If the piston has burned spots or soratches on its surface, cylinder noise is pro- duced and engine rotation becomes unsmooth, resulting in loss of engine power, Further, the piston is pat to seize at these points. Replace if badly worn, and repair burns or minor dofects with 400 emery paper. 9-6-2. Servicing Remove carbon depasits from the piston crown and ring grooves with a knife or broken piace of an old piston ting, Carbon deposits on the ‘crown increase compression and cause engine overheating, and those in the piston ring grooves make the movement of the piston rings un- smooth resulting in compression leakage. Fig, 8-6-7 Removing erbon 9-6-3. Installing AS the piston pin holes are off-center, the piston can be installed only in one direction. If it is installed bakwards, the scavenging ports will not align with the slots on the piston skirt, which affects engine performance badly. Be sure to install the piston with the arrow mark pointing toward the exhaust port. /Avrow mark Fig. 8-6-8 Arrow mark 8-7. Piston Rings 8-7-1. Removing Expand the ends of the ring with thumb nails ‘and remove the ring over the top of the piston from the opposite side, taking care not to break or twist the ring or damage the piston surface. 268-7-2, Inspecting End gap If the piston ring end gap is too large, com pression leaks, increasing fuel consumption, causing poor acceleration, hard starting, etc, To check the piston ring end gap, first insert the ring into the lower part of the cylinder, where wear is the smallest and then measure the end gap with a feeler gauge. If the clear ance is found to exceed the limit, the unit should be then replaced, Use a piston to insert the piston ring into the cylinder so that the ring is fitted square with the cylinder. Standard] Limit] Operation 0,15-0.36 mm End | (6.0069 {o,oa mn) | Replace en 0.0138 in) | 8-7-3, Installing ‘A, The piston rings on this engine are of key- stone type and tapered 7° on the upper surface. The most outstanding advantage of keystone type ring is to prevent carbon from accumulating on the upper and lower surfaces of the ring grooves of the piston and thus prevents ring sticking. Both the top and second rings are chrome-plated for higher resistance to wear, Fig, 8-7-2 Inserting plston ving into cylinder Fowler gauge Fla. 6-7-3 Measuring end gap Fig. 87-31 Piston rings Stamped mark Fig. 8-7-3-2 Stamped mark on piston ringB, Align the piston ring end gap with the pis: ton ring locating pin fitted in the piston ring groove. If the end gap is not at the locating pins or the rotation of the rings in the ring grooves is not smooth, the cylinder cannot be installed, 8-8. Piston Pin Bearing 8-8-1. Removing The piston pin bearing is installed on the conrod small end and its fit is loose, so it can be re moved by hand, 8-8-2. Inspecting To check the piston pin bearing for wear, fit the bearing into the small end of a new conrod, insert a new piston pin into the bearing and move the piston pin up and down. Replace the piston pin bearing with a new one if the play is over 0.045 mm (0.00177 in). 8-9. Flywheel Magneto The flywheel magneto is the power source of all the electrical equipment and consists of the magnetic flywheel rotor, which incorporates the contact breaker cam; and the startor assembly, which includes the primary coil, contact breaker and condenser for ignition operation, and the lamp coil for charging the battery and powering the lights. eating pin ject in Fig, 8-8-2 Checking paton pin boating 278-9-1. Removing Spegd ool “= Neboes0~s0112 Fig. 8-9-2 moving flywheel rotor Fig. 8-9-5 femoving magneto stotor 8-10. Drive Sprocket 810-1, Removing Fig. 810-1 Straightening sprocket washer with esl and harnmer 28nut —washer — sprocket ‘Speci too} spacer screwing Soracket mt nt with Fig 810-2 Engine sorackt& relative prt imme orl sprackat hale ‘specil tool No. 09820-60310), 810-2. Inspecting Inspect the engine sprocket teeth for wear. An excessively worn sprocket does not engage the drive chain properly and shortens the life of the drive chain, Replace the drive chain with a new one if excessively worn, 8-11, Oil pump & oil lines 8-11-1, Removing Fig. 8-112 Unscrewing oll pump fitting sero Fig, 811-3 Removing oi! pump Fig. 811-4 Removing oll pump crving piece811-2. Oil pump driving mechanism The oil pump is driven by the crankshaft through the primary pinion, primary gear, kick ‘par, kick idle gear, kick pinion and driving piece. ‘The speed reduction ratio between the crankshaft and the kick pinion is 6.13 : 1. As the oil pump is driven by the crankshalt, it pumps oil whenever the crankshaft rotates, that is whenever the engine is running regard less of whether the clutch is engaged or not. Fig, 8-1-6 Oil pump driving machantsen 308-11-23. Oil pump reduction ratio and performance curve The number of teeth, the reduction ratio and performance are as follows. Gear Teeth | oeeereme Primary pinion 16 y A Primary gear 57 ; Kick starter gear 18 § Kick starter idle gear | 29 i Kick starter pinion | 31 Oil pump reduction ratio: 7/16 X 31/18 = 6.13/1 Fig, 811-6 Oil pump performance aoe 1. The dual-opening oil pump: The dual-opening oil pump has been edopted in order that the required amount of oil can be pressure-fed to the necessary places. Aligning marks heck valves Fig. 811-7 0 pump Fig. 811-8 Oi outot pine The oil delivered to the right side outlet pipe is supplied to cylinder inlet passage through the hole on the left crankcase and the oil nozele, Fig, 8-11-9 Oil nozzle 31811-5, One-way valve mechanism, A one-way valve mechanism is contrived inside both of the oil outlet pipas to check the cil from flowing automatically from gravity or flowing back into the pump from pressure in the crank chamber after the oil has been dis charged from the pump into the crank chamber The check valve consists of @ sleel ball and a coil spring which presses the ball tightly against its seat. If pressure over 0,3ka/sq cm (4.3ib/sq in} is exerted the steel ball is pushed down, leav- ing gap to permit the oil discharged from the pump to flow into the crank chamber. 8-11-6. Inspecting and servicing Do not disassemble the oil pump as it is pre- cision made and its pumping performance may change after it is reassembled. A. Expelling air Check the Suzuki C.C.1. system for air especially when the oil pipes are disconnected for overhaul or at periodical inspections, If air is mixed in the il pipe, remove the air as follows If air is mixed in the pipe between the oil tank and the oil pump: Remove screw A in the main body of the oil pump, and let the contents flow out until the air in the pipe is exhausted. At the moment the air is completely exhausted, tighten the sorew firmly. If air is in the pipe between the oil pump and the inlet port or the left crank bearing Remove screw a or b and with an engine oll {iller containing two stroke engine oil inject the ll into the hole. The oil goes in easily Continue adding the oil until the air is removed, 2 Fig. 8-1 ‘Spring Fig. 8-11-10 Check valve operation Injecting engine oi to expel the air from all outlet pineB. Adjusting oil pump control cable If the oil pump control wire is too taut, more oil is consumed and, not only will the engine become bad, but in some extreme oases, the throttle valve may not open complete- ly. On the other hand, if the control wire is too loose, it will affect the engine becouse the required amount of oil will not reach it Fig. 8-11-14 Aligning oll pump asjusting marks Fig. 8-11-18 Adjusting oll pump contro! a, Adjust the throttle cable play to 0.5-1.0mm (,02-.04 inch) by turning the throttle cable adjustor located beneath the throttle grip housing, b. Adjust the oil pump by adjusting the pomp control cable adjuster so that the each marks on the oil pump lever align when the throttle is held wide open. Union bt 8-11-7. Tips on installing [ Before installing the union bolts, pour about 10cc (0.3 fl 02) of a specitied oil into the fitting holes on the crankcase left half. Be sure to use a gasket on either side of the union. Apply thread lock cement to the threads of the union bolts to prevent oil from oozing out. ‘2. When fitting the oil lines to the inlet and outlet, take care not to fit them in the wrong positions. The inlet oil fine is thicker then the outlet oil line, The upper hole on the cil Fig. 211=16 Oil pips guar pump is the inlet and the lower holes are the outlet, Placa gaskets on both sides of the oil line union, b. Do not overtighten the union bolts to prevent damaging the gaskets of the union, Oil pump union bolt | 26 kq-em (22 Ib-in, tightening torque 1.8 Ib-it)812. Clutch 8-12-1, Removing Fig 8 12-1 Removing orankeat right over iting teu Special tool pis2e_20210 Fig. 812-4 Removing latch spring pis by using Fig. 812-5 Removing eluteh plates uteh spring hook Special tal = + Fig, 8-12-6 Removing clutch release rod Fig. 812-7 Flattening sleeve hab nut lek, washer mFo sae ‘No, 09920. 52810 Fig 812-8 Untorewing clutch sleeve hub nut Fig. 8-12-10 Flomoving sees hub thrust wathor Fig. 8-12-11 Removing dren gear spring ‘nd primary driven gear 812-2. Mechanism The clutch is an important part of the engine, situated between the crankshaft and trans: mission gears, The clutch transmits or breaks transmission of the engine power to the gears. The clutch must have a long life and not stip or drag. The clutch mounted on this engine consists of five sats of cork and steel plates, clutch housing and sleeve hud, and is submerged in motor oil in the clutch chamber. This type of clutch is called @ wet, multi- plate clutch. As less pressure per unit is exerted and oil film is always formed between the plates, wear of the plates is held toa minimum, The clutch assembly is installed on the right end of the countershaft and the clutch release mechanism is installed on the crankcase left cover. The clutch cork and steel plates are retained in the clutch housing by the oluteh pressure plate. The clutch pressure plate is tixed to the clutch housing by Seven springs and spring pins, These seven clutch springs exert pressure on the pressure plate and thus hold the cork plates against the steel plates. The inside edges of the steel plates have teeth which engage with the outside splines of sleeve hub, The inside splines of the sleeve hub mesh with the splines on the countershatt so that the steel plates and sleeve hub turn with the countershaft. The outer edges of the cork plates have teeth which engage with the slots cn the clutch housing. The clutch housing is installed over the countershaft but it is not held by the splines so that it can rotate freely. 358-12--3, Exploded view of clutch Fig 8-12-12, Operation When the clutch is engaged the clutch springs (1) force the pressure plate (2) against the cork plate (3) and steel plates (4). The entire clutch is then held as @ single unit by frictional force. The primary pinion installed on the right end of the crankshaft drives the primary gear (5) riveted to the clutch housing (6), thus rotsting the clutch assembly The clutch assembly tums the transmission countershaft. When the clutch lever (7) mounted on the handlebar is squeezed the clutch wire (8) is pull- ed, lurning the release screw (8) in the release screw quide (10) so that the push rods (11) installed in the countershaft are pushed against the release rod (12) by the adjusting screw (13) which moves the pressure plate (2) out so tnat the clutch disengages, 368-12--4. Inspecting A. Clutch Cork Plates As the clutch has five cork plates and they are submerged in oil, wear is vory small. Aftor a long period, however, when the clutch plates become worn or warpod, the clutch will slip even if the clutch adjustment is correct, Measure the thickness and warp of each cork plate with calipers and a feeler gauge. Staneard Limit | Operation ‘3.0 men 28mm Thickness | (ont8 inh (101m | Replace ‘unde 0.4mm | 0.4mm | Warmest | (0.016 in) (2.076 in) | Mevleee B. Clutch Stee! Plate Four stee! plates are used and they have knurls on their surfaces to prevent the clutch from dregging in cold weather. Check the thickness and warp of each steel plate with calipers and a feeler gauge, Standerd | _timit | Operon Tem | 1S mm Thickness | (0,060 in} (0.089 int | Reelace ‘nda. amen wwuroaae | (aaao@ oy” Teron in | Revie C. Clutch Spring The clutch springs which have lost their tension also cause clutch slipping resulting in loss of power and rapid wear of the clutch plates. Remove the clutch springs from the clutch sleeve hub by turning them out by hand and measure their free length with calipers, | Standara Timi | Operation I, 28,9 mm "30.9 mm Free loot | 4.477 ml U.2t7iny | Replace When refitting the clutch springs, make sure that their bottom ends align with the clutch sleeve hub bottom surface and do not protrude, Use a square to check the clutch spring fitting, Fig, 8-12-13 Measuring cork plate thickness Foster sy 218 Meaniring tet plate warpage Fig, 8-12-18 measuring clutch spring fae Fig. 8-12-16 hacking clutch spring tt 37D. Play in axial direction If the play of the clutch housing in the axial direction becomes large, rattling noises is pro- duced. Check the play after fitting the clutch housing on the counter shaft as follows. First tighten the clutch sleeve hub, and then check it by moving the primary gear toward the axial direction atler fitting the dial gauge feeler on the surface of the clutch housing, Stendard T time Fi 812-17 Maas pay eal ‘axial pay | 217025 mm (03 mm sil play | (9.0039~ 0.0008 in) | 40.0118 inl 812-5. Tips on installing a. When installing the clutch pressure plate, align the positioning mark on the clutch pressure plate with the mark on the edge of the clutch sleeve hub, b. Inside the crankcase right cover is installed the countershatt oil seal. Be sure to install this oil seal to the right cover 80 a§ to face its lip toward the mating surface of the right cover. Make sure dirt is not clogged in the space behind the bearing, as oil enters the center hole of the countershaft through the space to lubricate the clutch components. When installing the crank- case right cover, make sure two dowel pins are Fis. 8-12-12 Counternate and ol set properly placed on the crankcase. 388-13. Kick Starter 8-13-1. Removing Fig, 513-1. Removing spring holder Fig, 2-13-2 Removing kick starter thatt sotina 8-13-2. Exploded view of kick system @ Sn Fig, 813-3 Removing spring holder 1. ick Startershate 2 Spring Guide 3. Spring Holder 4. Kick Starter Past 5 Pana Pin 6 Pav Spring 1. Paws Litter 8 Lifter Serow 9. Kick Starter Orive Gear N.T.=31 8 15, 10, Kick Shaft Spring 11 Thrust Washer 12, KickShatt RH Washer 16<305x0.5 13, Kick Drive Gear Washor 203271 14, Kick hate Wave Washer 16<305x1.5, 15, Drive Gear Oil Seal 5) 16. KieksShatt Oi Seat / 17, ick Starter Lever As'y 18, Lever Ruder813-3. Description ‘The model TS125 kick starter can be operated by pulling in the clutch lever even with the gears engaged, so long as the clutch is disengaged. It is not necessary to shift into neutral before starting the engine. This mechanism is called a primary kick starting system. The kick starting action is transmitted to the engine in the order of kick starter shaft, kick starter pinion, kick starter idle gear, kick sterter gear, primary gear, primary pinion and crankshaft, as shown in Fig, 813-5, The engine can be started regardless of gear position if the clutch is disengaged. Fig. 8-1-5 kick starter mechanism Inside the kick starter pinion is installed a ratchet mechanism consisting of a pawl, paw! roller and paw! spring. When the kick starter lever is depressed, the kick starter shaft lurns in a counterclockwise direction as seen from the lever end of the shaft, When the kick starter shaft turns counterclockwise, the kick starter paw! engages with the teeth machined on the inside of the kick starter pinion and the kick starter pinion turns, as the paw! moves at a right angle to it. Pkiek-statur paul spring @Kicksterter pinion Once the engine is started and the kick _@)Kick tatrer pawl roller”) Kick starter shaft starter lever is released, the kick starter. @ Kiek star paw! (ick starter shat stopoer shaft is returned to its original position by the return spring and the paw! is pushed back out of the way by the kick starter shaft stopper so that the engine revs, are not transmitted to the kick starter shatt. ‘he ek starter eased he ek ster er egress Fig. 212-6 Kick sartar ratchet mosnenismn 408-13-4, Inspecting A. Kick starter pinion & pawl Inspect the internal teeth of the kick starter pinion for wear. If they are excessively worn, the pawl does not engage with them properly and slips when the kick starter lever is operat ed, so that rotational power is not transmitted to the crankshaft. An excessively worn kick starter pawl also causes the same kind of trou- ble. Replace with new ones if they are worn, B. Kick sterter paw! pin & spring: Check the kick starter pawl pin by pushing it with 2 thumb to see if it operates properly in the hole on the kick starter shaft. If it does ‘not operate smoothly due to foreign matter in the hole or a defective spring, it causes rapid woar of the kick starter pinion internal teeth and the pawl as well as kick starter slippage. Clear foreign matter from the hole and replace a defective spring with a new one 8-13-5, Tips on disassembling and assembling ‘A. The kick starter shaft assembly can be removed from the crankcase easily by hand, but take care not to lose the thrust washers, kick pawl spring or kick paw! pin, When assembling the kick starter system, be sure to fit one thrust washer on either side of the kick starter shaft large section. When putting the pin into the hole, be sure to fil it with the flat end facing in ward. Fig. 813-7 Kick starter pinion & paw! Fig. 813-8 Checking starter pov roller Fig, ©-19-9 Installing kick starter shaft aB. When fitting the kick starter shaft return spring retainer and guide, pay attention to their fitting direction. (See Fig. 8—13~4) Before installing the kick starter shaft return spring, turn the shaft rightward all the way, Insert one end of the return spring into the hole on the crankcase and the other into the hole on the shaft by twisting about halt a turn with pliers 8-14. Gear Shifting Parts Outside Crankcase 814-1. Removing Fig, 8-141. Loosening gnu shifting ear pin Fetainr iting eran, Fig, 8-13-10 Installing kick starter shat return spring Fle. 6-14-3 Ramoving cam stoner pa set 42 Fig #14. 4 Removing com stopper partFig 8-145 Removing gear shifting shaft Fig, 8-146 Removing com gue 8-14-2, Inspecting Pow ture A, Gear shifting shett seeing Check the rivet calking of the shaft and arm joint to see if itis not loose, Replace the shaft complete if ts rivet calking is loose 8. Gear shifting shaft return spring ‘A gear shifting shaft return spring which has lost its tension can’t make the gear shifting , lever raturn to its normal position when the lever is released after shifting the gears. Check and replace the gosr shifting shaft roturn spring pig. -14-7A Guu sting shalt and if itis defective se pr C. Gear shifitng paw return spring An excessively stretched gear shifting pavil return spring makes gear shifting difficult Check the free length of the gear shifting paw return spring with vernier calipers. ‘Shaft com, {shat returo fering Standard free length | 55 mm (2.17 in) 18-14-3. Tips on installing Fit the gear shifting shaft return spring with Fla. 6-14-78 measuring pt rewuen spr the lessbent side down to the shaft, ing pr exuen spring ee Wrong Fin 8148 Fig. 814-9 Fitting ditcetion of goa shifting shat return spring 438-15. Primary Pinion 815-1. Removing Fig, 815-1 Straightoning primary pinion washer Note: When loosening the primary pinion nut, with the cylinder and piston in position, use a flywheel roter holder (Spocial tool 09830-40111) to prevent. the crankshaft from turning 815-2, Tips on installing Use @ torque wrench to tighten the primary Fig 818-4 Removing key pinion nut to the prescribed torque. Primary pinion nut tightening | 450 kg-cm (380 Ib-in, 32 lb-ft) torque Don't forget to bend one end of the washer Up tightly against the nut to prevent the nut from becoming loose, 448-16. Crankcase & Relative Parts 8+16-1. Removing Fig, 816-1. Removing erankease joining Fig. 8-16-2 Removing gear shifting carn row fromlolt cranes sopoer ‘Special took asta 92610- Special tool ‘05010-92810 Si Fig. 816-3 Fitting Special tool on erankshatt Fig, 8-164 Separating crankcase with special Note: When loosening the crankcase joining sorew, be sure to loosen them bit by bit in a crisscross fashion, Be sure to uso @ crankshaft remover (special tool (09910-92810) to separate the crank- case without damaging parts See that all the transmission compo: nents remain in the crankcase right hatf Don’t pry the crankcase open with a sorew driver, as this damages the join: ing surfaces, causing compression and ail to leak, Fig, 816-8 Crankease sparated Fig. 8-16-6 Crankeat inside view 45Fig, 8-16-7 Removing gasket Fig. 16-9 Removing teenometer oar soowe tot 8-16-2. Servicing A. Lubrication oll for crankshaft right bearing Outside the right crankcase is installed the oil reservoir plate. Make sure dirt is not clogged in the space behind the oil reservoir plate, as oil enters the hale of oil reserve chamber through the space to lubricate the right crank: shaft bearing. Ouresevoir Bit ett ite Fig, 2-16-12 Oil rosrvoir plate 46 Fig, 2-18-8 Removing wansnission parts Fig, 8-16-10 Removing tachometer driven ear seove Fig, 6-16-11 Tachometer drive ll serve chamber Fig. 8-16-12 Chancel of right erankenatt, bearing Isbrcation oiB, Drive shaft bush As the 18125 transmission is constructed so that the transmission oil in the gear box flows through the oil passage of the bushing and lubricates the bushing, make sure that any foreign matter doesn’t clog the passage. In addition, when replacing the bushing with new ‘one, it shoudl be fitted exactly as shown in Fig. 8-16-15, C. Bearing As the bearings are shrink fitted in the crank case, heat the crankcase with a burner to re- move or install them and the work can be done easily without damaging the crankcase and bearings. Heat the crankcase round about the bearing holes until bearings can be removed or installed by hand. Wash the bearing with cleaning solvent nd lubricate with motor oil before inspecting, Hold the bearing by the inner race with fingers, Tum the outer race and check to see that the outer race tums smoothly. If it does not turn lightly, quietly and smoothly, or if noise is heard, the bearing is defective and must be replaced with a new one, Fig, 18-18 Inspecting bell bearing 47D. Oil Seats A. Crankshaft oil seals The crankshaft is the heart of the engine and revolves to intake fuel mixture into the crankcase and compress it. If the oil seals are defective or damaged, fuel mixture will teak from the crankcase when it is compressed, resulting in less entering the combustion ‘chamber and thus causing loss of power and increased fuel consumption. B. Drive shaft and kick starter shaft oil seals The drive shaft and kick starter shaft oil seals prevent oi! from leaking form the gearbox and clutch chamber. i Removing and installing To remove the oil seals, insert the blade of an oil seal remover (special tool 09913- 50110) into the inside of the oil seal and lever it out. Be careful not to hold the blade against the oil seal lips in case the oil seal can stand further use, as this will damage the lips which are the most important part of the oil seal, Use the toal as instructed in Fig. 8-16-19. When installing the oil seals, first apply grease all around the lips and then embed the oil seals with the best size of bearing & oil seal installing tools (special tools, 09913-70110, 09913-70122). Alter inserting spacers into the oil seul, be sure to unbend the Tips ofthe oil seals, other: wise complete sealing can't be obtained and the wear of lips will be hastened. Special toot i Y it seal i Bear ae _-Brankcase Fig. 8-16-20 Applying areaie UL seal Mast a a DE ae TV ot see Fig, 8-16-21 Sectional view of oi sea Fig. 8-16-22 Fitting ol sea! 43,8-16-3. Installing ‘A. Install the crankshaft and gearbox com- ponents in the crankcase right halt. B, Fit a new crankcase gasket and twa dowel pins. C. Remove crankshaft oil crankcase, D. Checking to see that the two dowel pins are properly located, fit the lett half over the right helf. E, Install crankshaft assembling guide and connecting nut on left crankshaft. F. Press left crankcase down gently with @ crankshaft essembling tool (09910- 32810) to make it fit firmly over the right half without damaging parts, G. Top around drive shaft bearing hole of left crankcase with plastic hammer if necessary. H. After joining the crankcase halves, check to see if the crankshaft and transmission shafts turns smoothly and the gears are shifted properly. If not, open the case again and check the geerbox components for wrong installation. Repeat this open: assemble-rpocedure until all the shafts turn smoothly and the geers are shifted, |. Tighten the twelve crankcase joining sorews in a crisscross fashion, first the seven screws on the crank chamber and then the other five so that the crankcase is not warped, and compression and oil don't leak. J. After tightening the joining screws, check again to make sure the shafts turn smooth- Vy. K. Install new left crankshaft oil seal seal from left Note: When disassemble the engine, be sure to replace right and left crankshaft oil seals with new ones, Sh) Fig. 8-16-25 Installing gearbox components Fig, 8-16-24 Insaling two dowel pins Fig, 8-16-25 insaling crankcase gut — Special too! 08613 or10 Fig. 8-16-26 Romoving il seal trom lefterankease 49Fig. 8-16-27 Checking gearbox components ‘connecting ma Fig, 6-16-29 Insalling erankshat assombling toot fuide and connecting nut on lett Stance * Be Fig, 8-16-31 Tapping lefthalf it nacessary) Fig, 816-328 Tightaning crankeate ining sees 60 Fig, 8-16-28 Fiting left half ovar the right alt _- Special tool A810 92810 Fig, 8-16-90 Presing aft hat down wth ‘rankghaft aesomiling tool _/Special tol OE TONO Fig, 6-16-33 Installing lof crankshatt ol sel8-16—4. Crankshaft assembling tool When fitting the left crankcase over the right crankcase, be sure to use crankshaft assem- bling tool as follows, — 1 NED Scrat Ay Fig, 6-16-34 crankanate ssembling "ool Sonmeesng Guee ii Fig, 8-16-35 Special tools for crankcase installing9. TRANSMISSION 9-1, Exploded view of transmission é Fig 2-11 1. Counteshatt As'y 20, Ball Soaring 2 -Counterthatt 21, Driveshaft dash 32nd Drive Geor 22, Driveshaft OilSeal 5x7 4. 3rd Drive Gear 23, Countershatt Bearing Retniner 5. teh Drive Gear 24, Screw 6 Sth Drive Gear 25, Kick lla Gear Nt20 7, 4th Drive Gear ittip 25. Kick Driven Gear Nr-3t & Driver 27, riven Gear Booing 2135128 9, Ist Driven Gear Nev=33 28, Driven Gear Weerer —— 2110x0.8 10, 2nd briven Gear Not=29 20:1. Engine Sprocket 11, 3d Driven Gear N28 202, Engine Sprocket 12, 4th Driven Gear Nir23 203, Engine Sprocket 18, Sth Driven Gear N.r=20 30, Sprocket Spacer 20125K12.5, 14 Thoust Washer 31. Sprocket Nut 18, Countershafe Bearing LH Washer 15x30 32. Sprocket Washer 15. DriveshettCirelip 88, Sprocket O-Ring 17, Sed Driven Gear Wahser ‘AL DriveGhain Assy BazecteL 18, Ball Bearing 38. hain Joint 208 19, Ball BearingThe transmission consists of countershaft, drive shaft and gears inslalled on the shafts. The transmission of this motorcycle is of constantmesh, five speed, return shifting type and the reduction ratios are 2.75 in low, 1.81 in second, 1.25 in third, 1,00 in fourth and 0.80 in top. counter shaft 2 y. Driv hats Fla. 91-2 Neutral Fig. 9-1-3 Low speed Fig, 9-1-4 Second spec Fig. 9-1-5 Third speed Fig. 9-1-7 Top spent 9-2. Inspecting A. Gears Inspect the transmission gears for engagement, wear and damage of dog teeth each time the engine is disassembled. To inspect wear of the internal bushings, insert a relative new shaft into the gears. If they are wom or damaged excessively, replace them with new parts, 538, Shifting fork grooves The 4th, Sth driven and 3rd drive gear have grooves into which the gear shifting forks are placed. If the grooves are worn from friction with the forks and the clearance becomes ex- cessively large, travel of the 4th, Sth driven and rd drive gear decreases, 90 that they er difficult to engage with the adjacent gears and are easy to slip out of engagement. Measure ‘the clearence between the gear shifting forks ‘and grooves. Replace with new ones if it is over the limit. Fig. 9-1-8 Clears betwoon gow sifting fort ar groove Standard | Limit | Operation Fork/groove | 0.2-0.4mm | 0.8mm Clearance | (0.008- | (0,032 in) | Replace 0.016 in) 9-3. Counter shaft 'AS the second drive gear is press iftted on the counter shaft, disassemble the counter shaft assy. by using a hydraulic press to remove the second drive gear. When reassembling the counter shaft assy. apply motor oil to inner surface of seocnd drive gear and use a hydraulic press to install it on the shaft, After reassembl- ing the counter shaft, check to see if the 5th drive gear turns smoothly and be sure to measure the distance between ends of 1st drive Fle 8-1-8 Measuring length gear and second drive gear. (Fig. 9-1-9) 78.20 mm (3.079 in) "78.20 oom (3.079 in) ‘Standard 9-4, Installing (A) When installing the transmission gears, be sure not to install the gears on the shafts in the reverse direction (8) Many thrust washer are positioned to the side of the transmission gears, so, be care ful to fit the thrust washers in the correct position. {C) Between both the works of installing the transmission gears and fitting the right crankcase, lubricate all rotating parts and rubbing parts liberally with 20Ww/40 multigrade oll, Fill the transmission gear box with 550cc of 20WW/40 multigrade oil. ‘Check to see that gears can be shifted smoothly from 1st to top gear.9-2, Gear Shifting Parts Inside Crankease oe Fig 9-241 Gear Shitting Parts 9-2-1. Operation When the gear shifting lever is depressed, the gear shifting pawl on the gear shifting shaft pushes the gear shifting cam pin, turning the gear shifting cam, At this moment guided by the geor shifting fork guides which slide in the grooves machined on the cam drum, the gear shifting forks move in the axial direction, causing ‘the 4th, Sth driven and Srd drive gear to travel on the splines of the shafts so that each gearings are selected. Raising the gear shifting lever up four times from low will put the transmission in top. As the transmission of this motorcycle is a return type, the gaars have 1o be shifted back down through fourth, third, and sacond for neutral by depressing the gear shifting lever forward. An anti-jumping contrivance is designed into the gear shifting mechanism to prevent the gears from jumping over the position wanted due to rotational inertia of the goar shifting cam even when the gear shifting lever is operated with a rapid motion, 55